RANGER +2.5 2WD/4WD KIT PACKING SLIP DYNAMICS Thank you for puchasing our long travel kit. We pride ourselves on designing and fabricating our parts in our shop located in Las Vegas, Nevada. If you have any questions please feel free to email us at info@truetraveldynamics.com. Once again thank you for choosing True Travel Dynamics. Quantity Item Description PN# TTD982RGR4WD2 - One Ranger +2.5 4WD Long Travel Kit 2 2 2 pkg 3 pkg 2 pkg Driver Side Upper Control Arm (Assembled)* Passenger Side Upper Control Arm (Assembled)* Driver Side Lower Control Arm (Assembled)** Passenger Side Lower Control Arm (Assembled)** Fabricated Shock Mounts PN# TTD-AS - 4wd Axles Assembled (L&R) PN# TTD-050 - Upper Control Arm Spacers for 3/4 Heims PN# TTD-06 - - 5/8 Misalignment Spacers PN# TTD-002 - Upper Control Arm Uniball Adaptor Pins PN# TTD-072 - Lower Control Arm Uniball Tapered Spacers PN# TTD-003 - Tie Rod Extensions PN# TTD-00 - Shock Hardware Kit (8 - /2-20 x 2 3/4 bolts, 6 washers and 8 nuts) PN# TTD-009 - Limit Strap Hardware Kit (4 - /2-20 x /2 bolts, 8 washers, 4 nuts and 2 tabs for frame) PN# TTD-B6 - Brake Lines PN# TTD-L2 - Limit Straps PN# TTD-20 - LCA Hardware Kit * Includes 2 heim joints, 2 jam nuts and uniball bearing w/snap ring ** Includes uniball bearing w/snap ring, (4) Polyurethane Bushings PN# TTD-BUS, (2) Crush Sleeves PN# TTD-07 Upper Control Arm PN# TTD-AS Lower Control Arm PN# TTD-002 PN# TTD-B6 Shock Mounts PN# TTD-06 PN# TTD-050 PN# TTD-003 PN# TTD-072 PN# TTD-L2
CAREFULLY READ ALL DIRECTIONS BEFORE INSTALLATION Park your vehicle on level ground and apply the parking brake. Then chock the rear tires. Jack up the front of the truck, high enough so the front tires are off the ground and place jack stands securely under each side of the frame rails. Now set the truck down on the jack stands. Finally remove the wheels/tires from your truck. Removal of Factory Parts Place a jack under the driver side lower control arm to support it. Start by removing the nut holding the tie rod on, then hit the spindle to remove the tie rod. (4WD model trucks will need to use a 32mm socket to remove the nut holding the factory axle shaft.) Remove the nut and pinch bolt on the top of the spindle that is holding the ball joint on the factory upper arm. With a hammer hit the side of the spindle until the ball joint breaks free. Then loosen the nut holding the lower ball joint until it is at the end of the threads, do not remove completely. Again hit the spindle with a hammer to separate the ball joint from the spindle. Then remove the factory spindle, setting it aside. Lower the jack under the lower arm, and proceed to remove the upper arm, lower arm, sway bar, and shocks. Removal of Factory Upper Shock Mounts You must remove the top factory shock mount to make room for the new shock towers provided with the kit shown in Fig.. Kit Mock Up Next tack weld the shock mount in place. Do not fully weld at this time. Using the inside vertical section of the upper arm frame pocket, measure over 3/4" back (from the front arm pocket towards the rear of the truck) and place the shock tower. Shown in Figure 2-3. This is a good starting point while you mock up the rest of the suspension. You may need to modify the bracket holding the A/C evap dryer to clear the shock mount on the passenger side of the truck. 2 3
Then install the lower control arms using the factory hardware on the frame side and support it with a jack. If this is a 4WD kit, install the new extended axle PN# TTD-AS. Using one bolt from Lower Arm Hardware Kit PN# TTD-20, one spacer of PN# TTD-072 and one spacer from PN# TTD-06 attach the spindle to the lower arm. Torqe to 40 Ft. Lbs. 4 Next open up the Upper Arm Hardware Kit PN# TTD-002 and install the pin adaptor into top of the factory spindle and use the provided pinch bolt and nut to secure it into the spindle. Shown in Figure 4. Install the coilover shock and bypass shock. Install the bypass shock in the mount closest to the front of the truck and install the coilover in the mount toward the rear without the spring installed. Next using the factory bolts install the upper control arm on the frame side, then on the spindle side use the remaining hardware from PN# TTD-002 and one full package of spacers from PN# TTD-06. Now using the jack under the lower control arm (protect all powder coated surfaces) gently raise the suspension up until the shocks are fully compressed, making sure there is no interference and the suspension cycles smoothly. Adjust shock mounts as needed. Once you have verified this, you will need to remove the upper arm, shocks, spindles and axle shaft to finish weld the shock mounts to the frame. Weld every exposed seam completly as shown below. All welding should be done by a qualified individual or professional. Repeat these same processes for the driver side.
Final Assembly Now that both shock mounts are fully welded, you can proceeed to reinstall the lower control arms, then the spindles and axles (4wd only). Next install the coilover shocks with springs. Make sure to lower the lower control arm as much as you can, this will make it easier to install the shocks. After installation of both shocks, install the upper control arms and re-use the factory bolts and alignment cams. All suspension components should be double checked at this time to ensure all hardware is secure and tightened to proper torque specifications. If you have any questions regarding the installation of any of these products please call True Travel Dynamics for assistance. Installing the Tie-Rod Extensions To install the steering extensions PN# TTD-003 you must first remove the factory tie-rod ends from the tie-rods. Leave the factory jam nuts threaded onto the tie-rods, these will be tightened after installation of the extensions. The male side of the extension will thread into the facory tie-rod end. It is highly recommended that a thread locking compound such as RevLock Race Supplies 3 or equivalent be used on the male side of the extension. The female side will then be threaded onto the factory tie-rod. Be sure to achieve proper thread engagement onto the tie-rod. If the jam nut on the tie-rod needs to be threaded in toward the center of the truck to allow the extension to be threaded on properly please do so. A professional suspension/steering alignment will need to be done immediately after these suspension components are installed. The jam nuts should be tightened against the steering extension before driving or transporting the vehicle. Proper installation of the steering extension PN# TTD-003 is shown below in Figure 5. 5 Installation of the provided DOT approved extended brake lines PN# TTD-B6 should only be done by a professional or qualified individual. Rerouting/adjustment of the factory hard line brake line may be required in some applications due to shock mount location. Install brake lines with suspension at full droop (full extension of shocks) in order to ensure proper brake line slack at full extension. Limit straps PN# TTD-L2 need to be installed properly to ensure no component damage occurs. Use PN# TTD-009 and bolt the strap to the lower control arm. Raise the suspension up, compressing the shocks slightly. Loosely bolt the limit strap tab from PN TTD-009 to the top of the limit strap. Once suspension is raised, pull strap upward as tight as possible. Tack weld the provided tab in 2 places. Lower the suspension until the strap is tight and measure 7 of exposed shock shaft. If the strap is not tight or the measurment is not 7 of shaft exposed you will need to cut the tacks, remove the tab and repeat the process until it is correct. Once proper setup of strap is achieved you can unbolt the upper portion of the strap and finish weld the tabs. Re-install bolts and tighten to 90 Ft. Lbs. True Travel Dynamics highly recommends that any vehicle undergoing suspension changes, upgrades, or modifications be followed up with a suspension/steering alignment by a professional. On upper control arm applications that use Heim Joints the jam nuts must be tightened. Failure to tighten jam nuts could result in damage to the components. Be sure to check all jam nuts before and after an alignment as well as at every oil change for your vehicle in order to ensure your suspension products are being properly maintained. If you and have any questions or concerns regarding any of the steps provided in the instructions, questions about alignments, other True Travel Dynamics products or gereral inquiries please visit WWW.TRUETRAVELDYNAMICS.COM or call 702-94-0660. Thank you for your purchase.
THE FOLLOWING TERMS AND CONDITIONS APPLY TO ALL ORDERS PLACED WITH TRUE TRAVEL DYNAMICS (WEBSITE, PHONE, MAIL OR E-MAIL), EITHER DIRECTLY OR THROUGH A DEALER, CONSTITUTE THE ACKNOWLEDGEMENT AND ACCEPTANCE OF ALL THE CONDITIONS LISTED BELOW: All products sold or manufactured by TRUE TRAVEL DYNAMICS are intended for off-road use only. Our suspension systems are not to be modified from their original design in any way. TRUE TRAVEL DYNAMICS is not responsible or liable for any accidents, injuries or deaths that may occur from the use of any products offered. Installation of this system will alter the center of gravity of the vehicle and may increase the risk of a roll over as compared to stock. Customer assumes all liability in assuring that parts are correctly installed and maintained. No warranty is expressed or implied on all products sold or manufactured by TRUE TRAVEL DYNAMICS. We are not responsible for products that don't fit correctly on a vehicle which has sustained damage in an accident. Shipping and Delivery At this time, TRUE TRAVEL DYNAMICS ships merchandise to locations within the United States, Canada and Mexico but not to any international locations. The risk of loss and title for all merchandise ordered passes to the customer when the merchandise is delivered to the shipping carrier. Return Policy Returns are only accepted within 4 days from the date you receive the shipment If your purchase was done through one of our Authorized Dealers, please contact them directly to make your claim We are not responsible for shipping charges on returned products unless they are damaged in shipment** 20% restocking fee will be charged on all returns Deposits on custom orders are non-refundable Parts must be returned in the original package and condition as they were sent No returns on items that have been damaged during installation or have been installed If parts are damaged during the return shipping process, customer will be responsible for damages and True Travel Dynamics will deduct the value of damage from the amount owed to the customer for the return. Customer should make a claim with their shipping carrier. **Missing, Damaged or Defective Parts TRUE TRAVEL DYNAMICS goes through various stages of quality control to insure all parts are included and packaged correctly, however there may be an instance where something is looked over. If there is a missing or defective part, a claim must be made with TRUE TRAVEL DYNAMICS within 30 days of original purchase. Photos of the box's exterior and contents must be e-mailed along with a description of what's missing or defective. If the box/boxes has/have any holes, tears or damage from shipping, TRUE TRAVEL DYNAMICS will make a claim with the shipping carrier. For all returns please contact us via email and get a RMA Number to authorize your return. We will do our best to work with you and ensure your best needs are met. Maintenance After initial installation, parts may make a clunking or creaking sound until the heims, uniballs and bushings settle and are broken in. After a 50 mile break in period, you must go through and re-torque all of the bolts, and the bushings should be greased. This will increase the lifespan of the joints and help prevent them from making noise. Inspect these items periodically for unusual wear and replace if necessary. Replacement is necessary if any of the heims, uniballs or bushings have slop/play.